Continuous forming method and device for H-shaped FRP member

Abstract

A continuous forming method and device for an H-shaped FRP member for forming semi-hardened preimpregnated members produced by impregnating thermosetting resin to carbon fiber or glass fiber and the like into a predetermined H-shape. The forming device comprises of a device for mounting a plural number of bobbins having strip-shaped preimpregnated material spooled thereto, providing tension when pulling the impregnated material out from the bobbin. The device the shapes the preimpregnated material to a predetermined H-shape that feeds release films from four sides of upper, lower, left and right. The device then provides heat and pressure to the preimpregnated material from said four sides with a heating furnace for after-curing the preimpregnated material. The device then hauls and holds the preimpregnated material for cutting the cured product.

We claim:  
     
       1. A process for continuously forming flat sheets of thermosetting resin impregnated with carbon and/or glass fiber with the exterior surface protected by a first release film into an H-shaped FRP material, said process comprising: 
       hauling and holding said flat sheets of thermosetting resin progressively throughout the process;  
       removing said first release film from the flat sheets of thermosetting resin;  
       providing a second release film to the upper surface of a top flat sheet and to the lower surface of a bottom flat sheet of said flat sheets of thermosetting resin;  
       shaping said flat sheets of thermosetting resin to a pre-determined H-shape;  
       providing a third release film to the left and right exterior side surfaces of the H-shaped FRP material;  
       providing heat and pressure to the exterior surface of said H-shaped FRP material;  
       providing heat for after-curing of said H-shaped FRP material; and  
       cutting the H-shaped FRP material.  
     
     
       2. An apparatus for continuously forming flat sheets of thermosetting resin impregnated with carbon and/or glass fiber with the exterior surface protected by a first release film into an H-shaped FRP material, said apparatus comprising: 
       a means for hauling and holding said flat sheets of thermosetting resin progressively throughout the process;  
       a means for removing said first release film from the flat sheets of thermosetting resin;  
       a means for providing a second release film to the upper surface of a top flat sheet and to the lower surface of a bottom flat sheet of said flat sheets of thermosetting resin;  
       a means for shaping said flat sheets of thermosetting resin to a pre-determined H-shape;  
       a means for providing a third release film to the left and right exterior side surfaces of the H-shaped FRP material;  
       a means for providing heat and pressure to the exterior surface of said H-shaped FRP material;  
       a means for providing heat for after-curing of said H-shaped FRP material; and  
       a means for cutting the H-shaped FRP material.  
     
     
       3. The apparatus of  claim 2 , wherein said means for shaping flat sheets of thermosetting resin to a pre-determined H-shape is comprised of: 
       a means for forming two creases to two of said flat sheets of thermosetting resin;  
       a means for bending said flat sheets of thermosetting resin at the point of said creases to form an open-trapezoid-shape cross section;  
       a means for forming a U-shaped cross section from said open-trapezoid-shape cross section; and  
       a means for mutually fixing two U-shaped cross sections to form an H-shape cross section.  
     
     
       4. The apparatus of  claim 2 , wherein said means for hauling and holding is timed to haul and to hold said flat sheets of thermosetting resin at intermittent periods of time necessary for said means for providing heat and pressure to apply the necessary heat and pressure to form an H-shaped FRP material.